Orthopaedic instrument system including an instrument caddy and method for assembling a surgical instrument

ABSTRACT

An orthopaedic instrument system including an instrument caddy is disclosed. The instrument caddy is configured to receive one or more cutting broaches to house the cutting broaches between orthopaedic surgical procedures. The instrument caddy is also configured to be used during a surgical procedure to assist a user in assembling the cutting broach with another surgical instrument. A method of assembling a surgical instrument is also disclosed.

This application is a divisional of U.S. patent application Ser. No.15/830,457, now U.S. Pat. No. 10,478,262, which is herein incorporatedby reference in its entirety.

TECHNICAL FIELD

The present disclosure relates generally to orthopaedic instruments foruse in the performance of an orthopaedic joint replacement procedure,and, more particularly, to an instrument caddy for an orthopaedicsurgical instrument tray used in the performance of a knee replacementprocedure.

BACKGROUND

Joint arthroplasty is a well-known surgical procedure by which adiseased and/or damaged natural joint is replaced by a prosthetic joint.For example, in a total knee arthroplasty surgical procedure, apatient's natural knee joint is partially or totally replaced by aprosthetic knee joint or knee prosthesis. A typical knee prosthesisincludes multiple prosthetic components, including a tibial tray, afemoral component, and a polymer insert or bearing positioned betweenthe tibial tray and the femoral component. The tibial tray generallyincludes a plate having a stem extending distally therefrom, and thefemoral component generally includes a pair of spaced apart condylarelements, which include surfaces that articulate with correspondingsurfaces of the polymer bearing. The stem of the tibial tray isconfigured to be implanted in a surgically-prepared medullary canal ofthe patient's tibia, and the femoral component is configured to becoupled to a surgically-prepared distal end of a patient's femur.

During any knee surgery, the orthopaedic surgeon typically uses avariety of different orthopaedic surgical instruments such as, forexample, broaches, cutting blocks, reamers, drill guides, and othersurgical instruments to prepare the patient's bones to receive the kneeprosthesis. The instruments are generally organized within an instrumenttray that is accessible to the surgeon throughout the procedure. Duringthe procedure, the surgeon or other user removes various instrumentsfrom the tray for use in the procedure.

SUMMARY

According to one aspect of the disclosed embodiments, an orthopaedicinstrument system includes a cutting broach including a tapered bodyextending along a longitudinal axis from a base to a tip. A plurality ofcutting teeth are defined in the tapered body. An instrument caddy isconfigured to receive the cutting broach. The caddy includes a bottomwall, a first side wall extending upwardly from the bottom wall, and asecond side wall spaced apart from the first side wall and extendingupwardly from the bottom wall to define a storage chamber. The firstside wall includes an opening and a pair of surfaces extending inwardlyfrom the opening to define a groove sized to receive the base of thecutting broach. The pair of surfaces are shaped to engage the base ofthe cutting broach to inhibit rotation of the cutting broach about itslongitudinal axis. A slot aligned with the groove extends through thesecond side wall. The slot is sized to receive the tip of the cuttingbroach.

In some embodiments, a stem component may have an elongated body and amounting end sized to be received in an opening defined in an endsurface of the tip of the cutting broach to couple the stem component tothe cutting broach. When the cutting broach is positioned in the caddy,the end surface of the tip of the cutting broach may extend outwardlyfrom the slot to permit the stem component to be coupled to the cuttingbroach. In some embodiments, when the cutting broach is positioned inthe caddy, the mounting end of the stem component may be received withinthe slot to permit the stem component to be coupled to the cuttingbroach.

In some embodiments, the cutting broach may be a first cutting broach,the opening may be a first opening, and the slot may be a first slot.The caddy may include a second opening in the second sidewall and asecond pair of surfaces extending inwardly from the second opening todefine a second groove sized to receive a base of a second cuttingbroach. A second slot extending through the first sidewall may be sizedto receive a tip of the second cutting broach.

In some embodiments, the system may have a plurality of cuttingbroaches. The first side wall may have a plurality of grooves. Eachgroove may be sized to selectively receive a base of one of theplurality of cutting broaches. The caddy may have a plurality of slotsextending through the second side wall. Each slot may be aligned withone of the plurality of grooves and sized to receive a tip of one of theplurality of cutting broaches.

In some embodiments, an instrument tray may be sized and shaped toreceive the caddy.

In some embodiments, the caddy may have an end wall extending betweenthe first side wall and the second side wall. A handle may be formed inthe end wall. The handle may be an opening extending through the endwall. The handle may be a flange extending from the end wall.

In some embodiments, the cutting broach may be one of a femoral cuttingbroach and a tibial cutting broach.

According to another aspect of the disclosed embodiments, an orthopaedicinstrument system includes an instrument caddy configured to receive acutting broach. The caddy includes a bottom wall, a first side wallextending upwardly from the bottom wall, and a second side wall spacedapart from the first side wall and extending upwardly from the bottomwall to define a storage chamber. The first side wall includes anopening and a pair of surfaces extending inwardly from the opening todefine a groove sized to receive a base of the cutting broach. A slotaligned with the groove extends through the second side wall. The slotis sized to receive a tip of the cutting broach.

In some embodiments, the system may have a cutting broach having atapered body extending along a longitudinal axis from a base to a tip. Aplurality of cutting teeth may be defined in the tapered body. Anopening may be defined in an end surface of the tip.

In some embodiments, the slot may be defined by a pair of side wallsthat are spaced apart a distance greater than the diameter of theopening defined in the end surface of the tip of the cutting broach.

In some embodiments, the system may have a stem component having anelongated body and a mounting end sized to be received in the openingdefined in the end surface of the tip of the cutting broach to couplethe stem component to the cutting broach.

In some embodiments, the first side wall may have a plurality ofgrooves. Each groove may be sized to receive a base of one of aplurality of cutting broaches. A plurality of slots may extend throughthe second side wall. Each slot may be aligned with a groove of theplurality of grooves and be sized to receive a tip of one of theplurality of cutting broaches.

In some embodiments, the caddy may have an end wall extending betweenthe first side wall and the second side wall. A handle may be formed inthe end wall. The handle may be an opening extending through the endwall. The handle may be a flange extending from the end wall.

In some embodiments, the cutting broach may be at least one of a femoralcutting broach or a tibial cutting broach.

According to yet another aspect of the disclosed embodiments, a methodof assembling a surgical instrument includes selecting a cutting broachpositioned in an instrument caddy. The cutting broach includes a taperedbody extending along a longitudinal axis from a base to a tip and aplurality of cutting teeth defined in the tapered body. The method alsoincludes advancing a mounting end of a stem component through a slotextending through a side wall of the instrument caddy. The method alsoincludes coupling the mounting end of the stem component to the tip ofthe cutting broach positioned within the slot of the instrument caddy.The method also includes gripping the stem component to remove thecutting broach from the instrument caddy.

In some embodiments, coupling the mounting end of the stem component toa tip of the cutting broach positioned within the slot of the surgicalinstrument caddy may require threading the mounting end of the stemcomponent into the tip of the cutting broach. A pair of surfaces of thesurgical instrument caddy may engage the base of the cutting broach toinhibit rotation of the cutting broach about the longitudinal axis ofthe base during the threading of the mounting end of the stem componentinto the tip of the cutting broach.

BRIEF DESCRIPTION

The detailed description particularly refers to the following figures,in which:

FIG. 1 is an exploded view of an orthopaedic surgical instrument system;

FIG. 2 is a side elevation view of a tibial broach of the orthopaedicinstrument system of FIG. 1;

FIG. 3 is a top plan view of the tibial broach shown in FIG. 2;

FIG. 4 is a bottom plan view of the tibial broach shown in FIG. 2;

FIG. 5 is a side elevation view of a femoral broach of the orthopaedicinstrument system of FIG. 1;

FIG. 6 is a top plan view of the femoral broach shown in FIG. 5;

FIG. 7 is a bottom plan view of the femoral broach shown in FIG. 5;

FIG. 8 is a perspective view of a surgical instrument caddy;

FIG. 9 is a cross-sectional elevation view of the surgical instrumentcaddy taken along the line 9-9 in FIG. 8;

FIG. 10 is a cross-sectional elevation view of the surgical instrumentcaddy taken along the line 10-10 in FIG. 8;

FIG. 11 is a front elevation view of the surgical instrument caddy shownin FIG. 8 with a number of tibial broaches positioned in the surgicalinstrument caddy;

FIG. 12 is a top plan view of the surgical instrument caddy shown inFIG. 8 with a tibial broach and a stem component;

FIG. 13 is a view similar to FIG. 12 showing the stem componentassembled to the tibial broach;

FIG. 14 is a view similar to FIG. 13 showing the stem componentassembled to the tibial broach being removed from the surgicalinstrument caddy;

FIG. 15 is a perspective view of the surgical instrument caddypositioned within an orthopaedic instrument tray;

FIG. 16 is a perspective view of another embodiment of a surgicalinstrument caddy;

FIG. 17 is a cross-sectional elevation view of the surgical instrumentcaddy taken along the line 17-17 in FIG. 16;

FIG. 18 is a cross-sectional elevation view of the surgical instrumentcaddy taken along the line 18-18 in FIG. 16;

FIG. 19 is a front elevation view of the surgical instrument caddy shownin FIG. 16 with a number of femoral broaches positioned in the surgicalinstrument caddy;

FIG. 20 is a top plan view of the surgical instrument caddy shown inFIG. 16 with a femoral broach and a stem component;

FIG. 21 is a view similar to FIG. 20 showing the stem componentassembled to the femoral broach;

FIG. 22 is a view similar to FIG. 21 showing the stem componentassembled to the femoral broach being removed from the surgicalinstrument caddy.

DETAILED DESCRIPTION

While the concepts of the present disclosure are susceptible to variousmodifications and alternative forms, specific exemplary embodimentsthereof have been shown by way of example in the drawings and willherein be described in detail. It should be understood, however, thatthere is no intent to limit the concepts of the present disclosure tothe particular forms disclosed, but on the contrary, the intention is tocover all modifications, equivalents, and alternatives falling withinthe spirit and scope of the invention as defined by the appended claims.

Terms representing anatomical references, such as anterior, posterior,medial, lateral, superior, inferior, etcetera, may be used throughoutthe specification in reference to the orthopaedic implants andorthopaedic surgical instruments described herein as well as inreference to the patient's natural anatomy. Such terms havewell-understood meanings in both the study of anatomy and the field oforthopaedics. Use of such anatomical reference terms in the writtendescription and claims is intended to be consistent with theirwell-understood meanings unless noted otherwise.

Referring to FIG. 1, an orthopaedic surgical instrument system 10includes an instrument 12 that attaches to one of a plurality of cuttingbroaches 14. As described in greater detail below, the orthopaedicsurgical instrument system 10 includes surgical instrument caddies 120,300 that house the cutting broaches 14 between orthopaedic surgicalprocedures. Each of the instrument caddies 120, 300 is also configuredto be used during a surgical procedure to assist a user in assemblingeach cutting broach 14 with another surgical instrument such as, forexample, a stem component 64 or the instrument 12.

The plurality of cutting broaches 14 include a tibial cutting broach 30(shown in detail in FIGS. 2-4) and a femoral cutting broach 32 (shown indetail in FIGS. 5-7). Referring now to FIGS. 2-4, the tibial broach 30includes an outer surface 34 extending from a tip 36 to a base 38 alonga longitudinal axis 37. The outer surface 34 is tapered, with thediameter of the broach 30 decreasing from the base 38 to the tip 36. Aplurality of cutting teeth 40 are formed in the outer surface 34 and areconfigured to remove portions of the patient's tibia when the tibialbroach 30 is inserted into a medullary canal formed in the patient'stibia. The cutting teeth 40 are configured to engage the bonesurrounding the medullary canal when the broach 30 is inserted in themedullary canal. The cutting teeth 40 cover the outer surface 34 suchthat the tibial broach 30 cannot be easily picked up by a surgeon orother user without risk of the surgeon or other user cutting his/herhand. It should be appreciated that other broaches having differentconfigurations may be provided. For example, the outer diameter and/orlength of the broach may vary to produce different sized canals toaccommodate prosthetic components of different sizes.

The base 38 of the tibial broach 30 includes an oval-shaped outersurface 39 and a substantially planar top surface 42 defined within theoval-shaped outer surface 39. The minor axis of the oval-shaped outersurface 39 defines a width 31 of the tibial broach 30. A bore 44 havinga diameter 45 is defined in the top surface 42. Inner walls 46, 48extend downwardly from the top surface 42 and cooperate with a bottomwall 50 to define a slot 52 in the tibial broach 30. The slot 52 extendsthrough the outer surface 34 of the tibial broach 30. A flange 54extends between the inner walls 46, 48.

The tip 36 of the tibial broach 30 includes a circular outer surface 59and an end surface 55 defined within the outer surface 59. An opening 60is defined in the end surface 55 and has a diameter 61 that is less thana diameter 57 of the outer surface 59. A threaded inner wall 62 of theopening 60 is shaped to receive the stem component 64 (shown in FIG. 1).Referring to FIG. 1, the stem component 64 includes an elongated body 66that extends from an end 68 to a tip 70. A plurality of threads 72 aredefined on the end 68 to engage the threaded inner wall 62 of the tibialbroach 30. In some embodiments, the stem component 64 may be coupled tothe tibial broach 30 by other means, e.g. snap-fit fastener, boltedfastener, or bayonet fastener. In an exemplary embodiment, a pluralityof stem components 64 may be provided having different lengths anddiameters. For example, the diameter of the stem component 64 may varybetween 10 millimeters and 24 millimeters.

Referring to FIGS. 5-7, the femoral broach 32 includes an outer surface80 extending from a tip 82 to a base 84 along a longitudinal axis 83.The tip 82 of the femoral broach 32 includes a circular outer surface 81and an end surface 79 defined within the outer surface 81. An opening 86is defined in the end surface 79 and has a diameter 87 that is less thana diameter 89 of the outer surface 81. The opening 86 has a threadedinner wall 88 that engages the threads 72 of the stem component 64. Insome embodiments, the stem component 64 may be coupled to the femoralbroach 32 by other means, e.g. snap-fit fastener, bolted fastener, orbayonet fastener. The outer surface 80 is tapered, with the diameter ofthe broach 32 decreasing from the base 84 to the tip 82. A plurality ofcutting teeth 90 are formed in the outer surface 80 and are configuredto remove portions of the patient's femur when the femoral broach 32 isinserted into a medullary canal formed in the patient's femur. Thecutting teeth 90 are configured to engage the bone surrounding themedullary canal when the broach 32 is inserted in the medullary canal.The cutting teeth 90 cover the outer surface 80 such that the femoralbroach 32 cannot be easily picked up by a surgeon or other user withoutrisk of the surgeon or other user cutting his/her hand. It should beappreciated that other broaches having different configurations may beprovided. For example, the outer diameter and/or length of the broachmay vary to produce different sized canals to accommodate prostheticcomponents of different sizes.

The base 84 of the femoral broach 32 includes an outer surface 91including a pair of end surfaces 93 and a pair of side surfaces 95.Angled surfaces 97 extend between the end surfaces 93 and the sidesurfaces 95. A width 99 of the base 84 is defined between the sidesurfaces 95. A substantially planar top surface 100 is defined at thebase 84 within the outer surface 91. A bore 102 having a diameter 103 isdefined in the top surface 100. Inner walls 104, 106 extend downwardlyfrom the top surface 100 and cooperate with a bottom wall 108 to definea slot 110 that extends through the outer surface 80. A flange 112extends between the inner walls 104, 106.

Referring back to FIG. 1, the instrument 12 has a base 18 and a handle20 extending from the base 18. A plug 22 is secured to the base 18opposite the handle 20. A post 24 extends from the plug 22 and isconfigured to be received in the bore 44 of tibial broach 30 or the bore102 of femoral broach 32 when the instrument 12 is secured to broach 14.The instrument 12 includes a lever 26 configured to retain theinstrument 12 on the broach 14. In the illustrative embodiment, thelever 26 includes a flange 28 configured to engage the broach 14 whenthe post 24 is received in the broach 14. The flange 28 engages one ofthe flange 54 of the tibial broach 30 or the flange 112 of the femoralbroach 32. It should be appreciated that in other embodiments theinstrument 12 may include latches, pins, or other fasteners to securethe instrument 12 to the broach 14.

Referring now to FIG. 8, one of the surgical instrument caddies of thesystem 10 (i.e., the caddy 120) is shown. In the illustrativeembodiment, the caddy 120 is configured to receive a plurality of tibialbroaches 30 of different sizes, including the tibial broach 30 describedabove. As shown in FIG. 8, the caddy 120 is configured to house up tosix tibial broaches, with sizes that range from 29 millimeters to 69millimeters. It should be appreciated that other size ranges arepossible in other embodiments and the caddy may be configured to receiveadditional or fewer broaches.

The caddy 120 includes a bottom wall 122, a pair of outer walls 117,119, and a pair of end walls 132, 134 positioned at the ends of theouter walls 117, 119. The bottom wall 122, outer walls 117, 119, and endwalls 132, 134 are preferably formed from metal. As shown in FIGS. 9-10.Each of the end walls 132, 134 includes an inner opening 131 and anouter opening 133. Side surfaces 135 extend between the inner opening131 and the outer opening 133 to define a bore 137 through each of theend walls 132, 134. The bore 137 forms a handle 139 which may be used tolift the caddy 120. Also, a flange 136 extends inwardly from each endwall 132, 134. The flange 136 also forms a handle 138 that may be usedto lift the caddy 120.

Referring back to FIG. 8, a plurality of side walls 124 extends upwardlyfrom the bottom wall 122 to define a storage chamber 126. The side walls124 are positioned between the outer walls 117, 119 and the end walls132, 134. The side walls 124 are preferably formed from plastic. Theside walls 124 include a pair of longitudinal walls 128, 130. Asdescribed in greater detail below, the longitudinal walls 128, 130cooperate to define six broach carriers 140 that are configured toreceive the six tibial broaches 30. A broach carrier 142 is positionedadjacent the end wall 132. A second broach carrier 144 is positionednext to the broach carrier 142. Additional broach carriers 146, 148,150, and 152 are positioned between the broach carrier 144 and the endwall 134 with the broach carrier 152 positioned adjacent the end wall134. Each broach carrier 140 is configured to hold one of the tibialbroaches 30 during sterilization or storage between surgical procedures,as well as assist the surgeon or other user to assemble a broach with astem component and the instrument handle. In an exemplary embodiment,the broach carrier 142 is configured to retain a 29 millimeter tibialbroach 30, the broach carrier 144 is configured to retain a 37millimeter tibial broach 30, the broach carrier 146 is configured toretain a 45 millimeter tibial broach, the broach carrier 148 isconfigured to retain a 53 millimeter tibial broach, the broach carrier150 is configured to retain a 60 millimeter tibial broach, and thebroach carrier 152 is configured to retain a 69 millimeter tibialbroach. The broach carriers 144, 146, 148, 150, and 152 are capable ofretaining a smaller sized broach.

As shown in FIGS. 9-10, each broach carrier 140 includes a basereceptacle 121 configured to receive the base 38 of a tibial broach 30and a tip mount 123 configured to receive the tip 36 of the tibialbroach 30. In the illustrative embodiment, the orientations of thebroach carriers 140 alternate so that the broach carrier 144 has a basereceptacle 121 defined in the longitudinal wall 128 and a correspondingtip mount 123 defined in the opposite longitudinal wall 130, while thebroach carrier 142 has a base receptacle 121 defined in the longitudinalwall 130 and a corresponding tip mount 123 defined in the longitudinalwall 128. In the illustrative embodiment, the configuration of eachcarrier 140 (and hence each receptacle 121 and tip mount 123) issubstantially identical so that only a single carrier 140 will bedescribed in detail below.

Referring to FIG. 9, the base receptacle 121 of the broach carrier 144includes a groove 155 that is defined in an inner surface 141 (shown inFIG. 8) of the longitudinal wall 128. The groove 155 is sized to receivethe base 38 of a tibial broach 30. The base receptacle 121 also includesa channel 162 that is defined in an outer surface 143 (shown in FIG. 8)of the longitudinal wall 128. In the illustrative embodiment, thechannel 162 opens into the groove 155. The groove 155 is partiallydefined by a pair of side surfaces 151 that extend inwardly from anopening 145 formed in a top surface 147 of the longitudinal wall 128. Arounded bottom surface 153 extends between the side surfaces 151 suchthat the side surfaces 151 and the bottom surface 153 cooperate todefine the groove 155. The side surfaces 151 are spaced a distance 149that corresponds to the width 31 of the base 38 of the tibial broach 30,and the bottom surface 153 is shaped to correspond to the oval-shapedouter surface 39 of the base 38 of the tibial broach 30 so that thegroove 155 prevents rotation of the tibial broach 30 about itslongitudinal axis 37.

The channel 162 is partially defined by a pair of side surfaces 157extending inwardly from the opening 145. The side surfaces 157 arespaced a distance 154 that is less than the distance 149. The distance154 is greater than the diameter 45 of the bore 44 of the tibial broach30 so that the bore 44 is accessible through the channel 162. A roundedbottom surface 156 extends between the side surfaces 157. The bottomsurface 156 is spaced a distance 158 from the bottom surface 153. Thebottom surface 156 and the side surfaces 157 cooperate to define thechannel 162.

Referring to FIG. 10, the tip mount 123 of the broach carrier 144includes a slot 176 defined in an inner surface 170 (shown in FIG. 8) ofthe longitudinal wall 130. The slot 176 is sized to receive the tip 36of a tibial broach 30. The tip mount 123 also includes a channel 172that is defined in an outer surface 174 (shown in FIG. 8) of thelongitudinal wall 130. In the illustrative embodiment, the channel 172opens into the slot 176. The slot 176 is partially defined by pair ofside surfaces 178 that extend inwardly from an opening 180 formed in atop surface 182 of the longitudinal wall 130. The side surfaces 178 arespaced a distance 179. A rounded bottom surface 184 extends between theside surfaces 178 such that the side surfaces 178 and the bottom surface184 cooperate to define the slot 176. The bottom surface 184 is roundedto correspond to the rounded outer surface 59 of the tip 36 of thetibial broach 30.

Referring to FIG. 11, the channel 172 is partially defined by a pair ofside surfaces 190 extending inwardly from the opening 180. The sidesurfaces 190 are spaced a distance 192 that is less than the distance179. The distance 192 is greater than the diameter 61 of the opening 60of the tibial broach 30 so that the opening 60 of the tibial broach 30is accessible through the channel 172. A rounded bottom surface 194extends between the side surfaces 190. The bottom surface 194 is spaceda distance 196 from the bottom surface 184.

Referring back to FIG. 8, although the configuration of the carriers 140is substantially the same, the base receptacles 121 and tip mounts 123increase in size from the end wall 132 to the end wall 134 toaccommodate broaches of increasing size. Specifically, the basereceptacles 121 and tip mounts 123 of the broach carrier 152 adjacentend wall 134 are deeper than the base receptacle 121 and tip mount 123of the broach carrier 142 adjacent end wall 132. The groove 155, slot176, and channels 162 and 172 of the broach carrier 152 are deeper thanthe groove 155, slot 176, and channels 162 and 172 of the broach carrier142. Each of the intermittent broach carriers 144, 146, 148, 150 has adepth that is between the depth of the broach carrier 142 and the broachcarrier 152.

Referring to FIG. 11, the grooves 155 and slots 176 alternate along thelongitudinal wall 130. The bases 38 of respective tibial broaches 30 arepositioned within respective grooves 155 and accessible through thechannels 162. The distance 154 between the side surfaces 157 of thechannel 162 is greater than the diameter 45 of the bore 44 of the tibialbroach 30. Accordingly, the bore 44 is accessible through the channel162 such that the instrument 12 can be attached to the tibial broach 30while the tibial broach 30 is positioned within the caddy 120.Additionally, a size of the tibial broach 30 that may be printed on thetibial broach 30 is viewable through the channel 162. The tips 36 ofrespective tibial broaches 30 are positioned within respective slots 176and accessible through the channels 172. The distance 192 between theside surfaces 190 of the channel 172 is greater than the diameter 61 ofthe opening 60 in the tip 36 of the tibial broach 30. In that way, theopening 60 is accessible through the channel 172 such that the stemcomponent 64 can be attached to the tibial broach 30 while the tibialbroach 30 is positioned within the caddy 120.

In use, the caddy 120 is positioned within an orthopaedic instrumenttray 280, as illustrated in FIG. 15. The orthopaedic instrument tray 280includes a plurality of instruments 282 that are utilized with thetibial broach 30 during joint arthroplasty. The caddy 120 rests withinthe orthopaedic instrument tray 280 to provide the surgeon or other userwith access to the tibial broach 30 during the procedure. The caddy 120may be removed from the orthopaedic instrument tray 280 utilizing one ofthe handles 138, 139 and placed on a surgical table. By removing thecaddy 120 from the orthopaedic instrument tray 280, the tibial broach 30may be removed from the caddy 120 with the stem component 64, asdescribed below.

With the caddy 120 positioned outside of the orthopaedic instrument tray280, the surgeon selects a tibial broach 30 that is to be inserted intothe patient's tibia, i.e. a tibial cutting broach 30 is selected basedon a size of the tibial broach 30. The tip 36 of the tibial broach 30extends outwardly from the slot 176 so that the end 68 of the stemcomponent 64 may be aligned with the tip 36 of the tibial broach 30 fromeither the longitudinal wall 128 or longitudinal wall 130, asillustrated in FIG. 12. The stem component 64 is then secured to thetibial broach 30 by threading the threads 72 defined on the end 68 ofthe stem component 64 to the threaded inner wall 62 of the opening 60 ofthe tibial broach 30, as illustrated in FIG. 13. The side surfaces 151of the groove 155 engage the oval-shaped outer surface 39 of the base 38of the tibial broach 30 during advancement of the stem component 64 sothat the groove 155 prevents rotation of the tibial broach 30 about itslongitudinal axis 37 while the stem component is secured to the tibialbroach 30. The surgeon or other user then lifts the stem component 64 tolift the tibial broach 30 from the caddy 120 as illustrated in FIG. 14.By lifting the tibial broach 30 via the stem component 64, the surgeonor other user avoids contacting the cutting teeth 40 formed in the outersurface 34 of the tibial broach 30. If the surgeon chooses to selectanother sized tibial broach 30, the surgeon or other user may eitherattach the second stem component 64 of the same size to another tibialbroach 30 or position the removed tibial broach 30 back into the caddy120, unscrew the stem component 64, and attach the stem component 64 toanother tibial broach 30. Alternatively, the surgeon or other user mayprepare a second tibial broach 30 with a second stem component 64 whilea first tibial broach 30 is in use. The second tibial broach 30 is leftin the caddy 120 while the first tibial broach 30 is in use. The surgeonor other user may then remove the second tibial broach 30 when neededwithout having to pause the procedure to secure the second stemcomponent 64.

Referring now to FIG. 16, another surgical instrument caddy of thesystem 10 (i.e., the caddy 300) is shown. In the illustrativeembodiment, the caddy 300 is configured to receive a plurality offemoral broaches 32 of different sizes, including the femoral broach 32described above. As shown in FIG. 16, the caddy 300 is configured tohouse up to six femoral broaches 32, with sizes that range from 30millimeters to 55 millimeters. It should be appreciated that other sizeranges are possible in other embodiments and the caddy may be configuredto receive additional or fewer broaches.

The caddy 120 includes a bottom wall 302, a pair of outer walls 303,305, and a pair of end walls 312, 314 positioned at the ends of theouter walls 303, 305. The bottom wall 302, outer walls 303, 305, and endwalls 312, 314 are preferably formed from metal. As shown in FIGS.17-18. Each of the end walls 312, 314 includes an inner opening 316 andan outer opening 318. Side surfaces 320 extend between the inner opening316 and the outer opening 318 to define a bore 322 through the end walls312, 314. The bore 322 forms a handle 324 which may be used to lift thecaddy 300. Also, a flange 326 extends inwardly from each end wall 312,314. The flange 326 also forms a handle 328 that may be used to lift thecaddy 300.

Referring back to FIG. 16, a plurality of side walls 304 extendsupwardly from the bottom wall 302 to define a storage chamber 306. Theside walls 304 are positioned between the outer walls 303, 305 and theend walls 312, 314. The side walls 304 are preferably formed fromplastic. The side walls 304 include a pair of longitudinal walls 308,310. As described in greater detail below, the longitudinal walls 308,310 cooperate to define six broach carriers 330 that are configured toreceive the six femoral broaches 32. A broach carrier 332 is positionedadjacent the end wall 312. A second broach carrier 334 is positionednext to the broach carrier 330. Additional broach carriers 336, 338,340, and 342 are positioned between the broach carrier 334 and the endwall 314 with the broach carrier 342 positioned adjacent the end wall314. The longitudinal wall 310 has a stepped configuration such that alength of each broach carrier 330 increases in size from the broachcarrier 332 to the broach carrier 342. Each broach carrier 330 isconfigured to hold one of the femoral broaches 32 during sterilizationor storage between surgical procedures, as well as assist the surgeon orother user to assemble a broach with a stem component and the instrumenthandle. In an exemplary embodiment, the broach carrier 332 is configuredto retain a 30 millimeter femoral broach 32, the broach carrier 334 isconfigured to retain a 35 mm femoral broach 32, the broach carrier 336is configured to retain a 40 mm femoral broach 32, the broach carrier338 is configured to retain a 45 mm femoral broach 32, the broachcarrier 340 is configured to retain a 50 mm femoral broach 32, and thebroach carrier 342 is configured to retain a 55 millimeter femoralbroach 32. Each broach carrier 334, 336, 338, 340, and 342 is capable ofretaining a smaller sized broach.

As shown in FIGS. 17-18, each broach carrier 330 includes a basereceptacle 360 configured to receive the base 84 of a femoral broach 32and a tip mount 362 configured to receive the tip 82 of the femoralbroach 32. Each broach carrier 330 has a base receptacle 360 defined inthe longitudinal wall 308 and a corresponding tip mount 362 defined inthe opposite longitudinal wall 310. In the illustrative embodiment, theconfiguration of each carrier 330 (and hence each receptacle 360 and tipmount 362) is substantially identical so that only a single carrier 330will be described in detail below.

Referring to FIG. 17, the base receptacle 360 of the broach carrier 334includes a groove 361 that is defined in an inner surface 363 (shown inFIG. 16) of the longitudinal wall 308. The groove 361 is sized toreceive the base 84 of a femoral broach 32. The base receptacle 360 alsoincludes a channel 364 that is defined in an outer surface 366 (shown inFIG. 16) of the longitudinal wall 308. In the illustrative embodiment,the channel 364 opens into the groove 361. The groove 361 is partiallydefined by pair of side surfaces 335 that extend inwardly from anopening 370 formed in a top surface 372 of the longitudinal wall 308. Anangled surface 374 extends from each side surface 335, and roundedbottom surface 376 extends between the angled surfaces 374 such that theside surfaces 335, the angled surfaces 374, and the bottom surface 376cooperate to define the groove 361. The side surfaces 335 are spaced adistance 380 that corresponds to the width 99 of the base 84 of thefemoral broach 32, and the angled surfaces 374 are shaped to correspondto the angled surfaces 97 of the base 84 of the femoral broach 32 sothat the groove 361 prevents rotation of the femoral broach 32 about itslongitudinal axis 83.

The channel 364 is partially defined by a pair of side surfaces 400 thatextend inwardly from the opening 370. The side surfaces 400 are spaced adistance 402 that is less than the distance 380. The distance 402 isgreater than the diameter 103 of the bore 102 of the femoral broach 32so that the bore 102 is accessible through the channel 364 and theinstrument 12 can be attached to the femoral broach 32. Additionally, asize of the femoral broach 32 that may be printed on the femoral broach32 is viewable through the channel 364. A rounded bottom surface 404(shown in FIG. 16) extends between the side surfaces 400. The bottomsurface 404 is spaced from the bottom surface 404. The bottom surface404 and the side surfaces 400 cooperate to define the channel 364.

Referring to FIG. 18, the tip mount 362 of the broach carrier 334includes a slot 410 that is defined in an inner surface 412 (shown inFIG. 16) of the longitudinal wall 310. The slot 410 is sized to receivethe tip 82 of a femoral broach 32. The tip mount 362 also includes achannel 414 that is defined in an outer surface 416 (shown in FIG. 16)of the longitudinal wall 310. In the illustrative embodiment, thechannel 414 opens into the slot 410. The slot 410 is partially definedby pair of side surfaces 420 that extend inwardly from an opening 422formed in a top surface 424 of the longitudinal wall 310. The sidesurfaces 420 are spaced a distance 426. A rounded bottom surface 428extends between the side surfaces 420 such that the side surfaces 420and the bottom surface 428 cooperate to define the slot 410. The bottomsurface 428 is rounded to correspond to the rounded outer surface 80 ofthe tip 82 of the femoral broach 32.

Referring to FIG. 19, the channel 414 is partially defined by a pair ofside surfaces 440 that extend inwardly from the opening 422. The sidesurfaces 440 are spaced a distance 442 that is greater than the distance426. The distance 442 is also greater than the diameter 87 of theopening 86 of the femoral broach 32 so that the opening 60 of thefemoral broach 32 is accessible through the channel 414. A roundedbottom surface 444 extends between the side surfaces 440. The bottomsurface 444 is spaced a distance 446 from the bottom surface 428.

The tips 82 of respective femoral broaches 32 are positioned withinrespective slots 410 and accessible through the channels 414. Thedistance 442 between the side surfaces 440 of the channel 414 is greaterthan the diameter 87 of the opening 86 in the tip 82 of the femoralbroach 32. Accordingly, the opening 86 is accessible through the channel414 such that the stem component 64 can be attached to the femoralbroach 32 while the femoral broach 32 is positioned within the caddy300.

Referring back to FIG. 16, from the end wall 312 to the end wall 314,the base receptacles 360 and tip mounts 362 increase in size.Specifically, the base receptacles 360 and tip mounts 362 of the broachcarrier 342 adjacent end wall 314 are deeper than the base receptacle360 and tip mount 362 of the broach carrier 332 adjacent end wall 312.The groove 361, slot 410, and channels 364 and 414 of the broach carrier342 are deeper than the groove 361, slot 410, and channels 364 and 414of the broach carrier 332. Each of the intermittent broach carriers 334,336, 338, 340 has a depth that is between the depth of the broachcarrier 332 and the broach carrier 342.

In use, the caddy 300 is positioned within an orthopaedic instrumenttray, similar to the tray 280 shown in FIG. 15. The caddy 300 may beremoved from the orthopaedic instrument tray utilizing one of thehandles 324, 328 and placed on a surgical table. By removing the caddy300 from the orthopaedic instrument tray, the femoral broach 32 may beremoved from the caddy 300 with the stem component 64, as describedbelow.

With the caddy 300 positioned outside of the orthopaedic instrument traythe surgeon or other user selects a femoral broach 32 that is to beinserted into the patient's femur, i.e. a femoral cutting broach 32 isselected based on a size of the femoral broach 32. The tip 82 of thefemoral broach 32 extends outwardly from the slot 410 so that the end 68of the stem component 64 may be aligned with the tip 82 of the femoralbroach 32 from the second longitudinal wall 310, as illustrated in FIG.20. The stem component 64 is aligned with the appropriate femoral broach32 and secured to the femoral broach 32 by threading the threads 72defined on the end 68 of the stem component 64 to the threaded innerwall 88 of the opening 86 of the femoral broach 32, as illustrated inFIG. 21. The side surfaces 335 of the groove 361 engage the sidesurfaces 95 of the femoral broach 32, and the angled surfaces 374 engagethe angled surfaces 97 of the femoral broach 32 so that the groove 361prevents rotation of the femoral broach 32 about its longitudinal axis83 while the stem component is secured to the femoral broach 32. Thesurgeon or other user may then lift the stem component 64 to lift thefemoral broach 32 from the caddy 300 as illustrated in FIG. 22. Bylifting the femoral broach 32 via the stem component 64, the surgeon orother user avoids contacting the cutting teeth 90 formed in the outersurface 80 of the femoral broach 32. If the surgeon or other userchooses to select another sized femoral broach 32, the surgeon or otheruser may either attach a second stem component 64 of the same size toanother tibial broach 30 or may position the removed femoral broach 32back into the caddy 300, unscrew the stem component 64, and attach thestem component 64 to another femoral broach 32. Alternatively, thesurgeon or other user may prepare a second femoral broach 32 with asecond stem component 64 while a first femoral broach 32 is in use. Thesecond femoral broach 32 is left in the caddy 120 while the firstfemoral broach 32 is in use. The surgeon or other user may then removethe second femoral broach 32 when needed without having to pause theprocedure to secure the second stem component 64.

While the disclosure has been illustrated and described in detail in thedrawings and foregoing description, such an illustration and descriptionis to be considered as exemplary and not restrictive in character, itbeing understood that only illustrative embodiments have been shown anddescribed and that all changes and modifications that come within thespirit of the disclosure are desired to be protected.

There are a plurality of advantages of the present disclosure arisingfrom the various features of the method, apparatus, and system describedherein. It will be noted that alternative embodiments of the method,apparatus, and system of the present disclosure may not include all ofthe features described yet still benefit from at least some of theadvantages of such features. Those of ordinary skill in the art mayreadily devise their own implementations of the method, apparatus, andsystem that incorporate one or more of the features of the presentinvention and fall within the spirit and scope of the present disclosureas defined by the appended claims.

The invention claimed is:
 1. A method of assembling a surgicalinstrument for use in cutting a medullary canal, the method comprising:selecting a cutting broach positioned in an instrument caddy having afirst sidewall extending upwardly from a bottom wall and a second sidewall, opposite the first side wall, extending upwardly from the bottomwall, the cutting broach including (i) a tapered body extending along alongitudinal axis from a base to a tip and (ii) a plurality of cuttingteeth defined in the tapered body, wherein the base of the cuttingbroach is received in a groove defined in the first sidewall and the tipof the cutting broach is received in a slot extending through the secondside wall opposite the groove, advancing a mounting end of a stemcomponent through the slot extending through the second side wall of theinstrument caddy, coupling the mounting end of the stem component to thetip of the cutting broach positioned within the slot of the instrumentcaddy, and gripping the stem component to remove the cutting broach fromthe instrument caddy.
 2. The method of claim 1, wherein: coupling themounting end of the stem component to the tip of the cutting broachpositioned within the slot of the surgical instrument caddy includesthreading the mounting end of the stem component into the tip of thecutting broach, and a pair of surfaces of the surgical instrument caddythat define the groove engage the base of the cutting broach to inhibitrotation of the cutting broach about the longitudinal axis of the baseduring the threading of the mounting end of the stem component into thetip of the cutting broach.
 3. The method of claim 1, further comprisinginserting the cutting broach into a medullary canal of a patient's femurto remove bone from the patient's femur.
 4. The method of claim 3,further comprising: removing the cutting broach from the medullarycanal; and gripping the stem component to insert the cutting broach intothe instrument caddy.
 5. The method of claim 4, wherein the cuttingbroach is a first cutting broach positioned in the instrument caddy andthe slot is a first slot extending through the second side wall of theinstrument caddy, the method further comprising: advancing the mountingend of the stem component through a second slot extending through thesecond side wall of the instrument caddy, coupling the mounting end ofthe stem component to a tip of a second cutting broach positioned withinthe second slot of the instrument caddy, and gripping the stem componentto remove the second cutting broach from the instrument caddy.
 6. Themethod of claim 5, wherein the second cutting broach is larger than thefirst cutting broach.
 7. The method of claim 5, wherein: coupling themounting end of the stem component to the tip of the second cuttingbroach positioned within the second slot of the surgical instrumentcaddy includes threading the mounting end of the stem component into thetip of the cutting broach.
 8. The method of claim 5, further comprisinginserting the second cutting broach into the medullary canal of thepatient's femur to remove additional bone from the patient's femur. 9.The method of claim 8, further comprising: removing the second cuttingbroach from the medullary canal; and gripping the stem component toinsert the second cutting broach into the instrument caddy.
 10. A methodof assembling a surgical instrument for use in cutting a medullarycanal, the method comprising: selecting a first cutting broachpositioned in an instrument caddy housing a plurality of cuttingbroaches, the instrument caddy including a first sidewall extendingupwardly from a bottom wall and a second side wall, opposite the firstside wall, extending upwardly from the bottom wall, and the firstcutting broach including (i) a tapered body extending along alongitudinal axis from a base to a tip and (ii) a plurality of cuttingteeth defined in the tapered body, wherein the base of the first cuttingbroach is received in a first groove defined in the first sidewall andthe tip of the first cutting broach is received in a first slotextending through the second side wall opposite the first groove,advancing a mounting end of a stem component through the first slotextending through the second side wall of the instrument caddy, couplingthe mounting end of the stem component to the tip of the first cuttingbroach positioned within the first slot of the instrument caddy,gripping the stem component to remove the first cutting broach from theinstrument caddy, gripping the stem component to return the firstcutting broach to the instrument caddy, selecting a second cuttingbroach, the second cutting broach including (i) a tapered body extendingalong a longitudinal axis from a base to a tip and (ii) a plurality ofcutting teeth defined in the tapered body, wherein the tapered body ofthe second cutting broach is larger than the tapered body of the firstcutting broach, wherein the base of the second cutting broach isreceived in a second groove defined in the first sidewall and the tip ofthe second cutting broach is received in a second slot extending throughthe second side wall opposite the second groove, advancing the mountingend of the stem component through the second slot extending through thesecond side wall of the instrument caddy, coupling the mounting end ofthe stem component to the tip of the second cutting broach positionedwithin the second slot of the instrument caddy, and gripping the stemcomponent to remove the second cutting broach from the instrument caddy.11. The method of claim 10, wherein: coupling the mounting end of thestem component to the tip of the first cutting broach positioned withinthe first slot of the surgical instrument caddy includes threading themounting end of the stem component into the tip of the first cuttingbroach, and a first pair of surfaces of the surgical instrument caddythat define the first groove engage the base of the first cutting broachto inhibit rotation of the first cutting broach about the longitudinalaxis of the base during the threading of the mounting end of the stemcomponent into the tip of the first cutting broach.
 12. The method ofclaim 10, wherein: coupling the mounting end of the stem component tothe tip of the second cutting broach positioned within the second slotof the surgical instrument caddy includes threading the mounting end ofthe stem component into the tip of the second cutting broach, and asecond pair of surfaces of the surgical instrument caddy that define thesecond groove engage the base of the second cutting broach to inhibitrotation of the second cutting broach about the longitudinal axis of thebase during the threading of the mounting end of the stem component intothe tip of the second cutting broach.
 13. The method of claim 10,further comprising inserting the first cutting broach into a medullarycanal of a patient's femur to remove bone from the patient's femur. 14.The method of claim 13, further comprising inserting the second cuttingbroach into the medullary canal of the patient's femur to removeadditional bone from the patient's femur.
 15. The method of claim 10,further comprising gripping the stem component to return the secondcutting broach into the instrument caddy.
 16. A method of assembling asurgical instrument for use in cutting a medullary canal, the methodcomprising: selecting a cutting broach positioned in an instrument caddyhaving a first sidewall extending upwardly from a bottom wall and asecond side wall, opposite the first side wall, extending upwardly fromthe bottom wall, the cutting broach including (i) a tapered bodyextending along a longitudinal axis from a base to a tip and (ii) aplurality of cutting teeth defined in the tapered body, wherein the baseof the cutting broach is received in a groove defined in the firstsidewall and the tip of the cutting broach is received in a slotextending through the second side wall opposite the groove, advancing amounting end of a stem component through the slot extending through thesecond side wall of the instrument caddy, coupling the mounting end ofthe stem component to the tip of the cutting broach positioned withinthe slot of the instrument caddy, wherein when the cutting broach ispositioned in the caddy, the end surface of the tip of the cuttingbroach extends outwardly from the slot to permit the stem component tobe coupled to the cutting broach, and gripping the stem component toremove the cutting broach from the instrument caddy.
 17. The method ofclaim 16, wherein: coupling the mounting end of the stem component tothe tip of the cutting broach positioned within the slot of the surgicalinstrument caddy includes threading the mounting end of the stemcomponent into the tip of the cutting broach, and a pair of surfaces ofthe surgical instrument caddy that define the groove engage the base ofthe cutting broach to inhibit rotation of the cutting broach about thelongitudinal axis of the base during the threading of the mounting endof the stem component into the tip of the cutting broach.
 18. The methodof claim 16, further comprising inserting the cutting broach into amedullary canal of a patient's femur to remove bone from the patient'sfemur.
 19. The method of claim 18, further comprising: removing thecutting broach from the medullary canal; and gripping the stem componentto insert the cutting broach into the instrument caddy.
 20. The methodof claim 19, wherein the cutting broach is a first cutting broachpositioned in the instrument caddy and the slot is a first slotextending through the second side wall of the instrument caddy, themethod further comprising: advancing the mounting end of the stemcomponent through a second slot extending through the second side wallof the instrument caddy, coupling the mounting end of the stem componentto a tip of a second cutting broach positioned within the second slot ofthe instrument caddy, wherein when the second cutting broach ispositioned in the caddy, the end surface of the tip of the secondcutting broach extends outwardly from the second slot to permit the stemcomponent to be coupled to the second cutting broach, and gripping thestem component to remove the second cutting broach from the instrumentcaddy.